Manufacturable geometries for thermal management of complex three-dimensional shapes

A method to control the thermal properties of a solid structure, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstock onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern, incorporating voids and material than said one or more feedstocks within said pattern to construct a solid structure having controlled thermal properties.

A method to embed hollow and multi material structures within a normally solid component, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstock onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern that creates voids or regions containing materials other than said one or more feedstocks, to construct a solid component having hollow and multi material structures therein.

A method to locally control the thermal history of a three dimensional structure, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstocks onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern incorporating regions of voids and/or materials other than said one or more feedstocks to construct a three dimensional structure with a particular thermal history, thereby forming the three dimensional structure with a particular thermal history.

A method to provide high efficient heat transfer within a three dimensional structure, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstock onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern incorporating regions of voids and/or materials other than said one or more feedstocks effective to control heat transfer while constructing said three dimensional structure.

A method to create components that allow thermal characteristics of a three dimensional structure to be engineered into a component, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstock onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern, incorporating embedded voids or regions of varying materials, to construct said three dimensional structure.

A method to control pressure drop across embedded features in a three dimensional structure, said method comprising:

• a. subjecting one or more feedstocks to a material deposition process and depositing said feedstock onto a substrate while heating the one or more feedstocks with a laser simultaneously with feedstock deposition onto the substrate;
• b. repeating step a. sufficient times in a defined, layerwise pattern in which the cross-section area and length of individual embedded structures are approximately equal in order to provide uniform flow characteristics and pressure in said three dimensional structure.